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Scriet (Agriculure Engineering), Ccsu Meerut Machine Desgn (Unit 3 Helical Gears, Lecture 5)
Scriet (Agriculure Engineering), Ccsu Meerut Machine Desgn (Unit 3 Helical Gears, Lecture 5)
Lecture 5
Contents
11.1 Helical gears – an introduction
11.2 Helical gears – Kinematics
11.3 Helical gears – geometry and nomenclature
11.4 Helical gears – force analysis
11.5 Helical gears – bending stress
11.6 Helical gears – contact stress
11.7 Crossed helical gears
11.7.1 Tips for crossed helical gear design
In spur gears Fig.11.1 dealt earlier, the teeth are parallel to the axis whereas in
helical gears Fig.11.2 the teeth are inclined to the axis. Both the gears are transmitting
power between two parallel shafts.
Crossed helical gears As in Fig. 11.6 are used for transmitting power between two non-
parallel, non-intersecting shafts. Common application is distributor and pump drive from
cam shafts in automotive engines.
When two helical gears are engaged as in the Fig. 11.7, the helix angle has to be the
same on each gear, but one gear must have a right-hand helix and the other a left-hand
helix.
Fig.11.8 Illustration of helical gear tooth formation
The shape of the tooth is an involute helicoid as illustrated in the Fig. 11.8. If a
paper piece of the shape of a parallelogram is wrapped around a cylinder, the angular
edge of the paper becomes the helix. If the paper is unwound, each point on the angular
edge generates an involute curve. The surface got when every point on the edge
generates an involute is called involute helicoid. In spur gear, the initial contact line
extends all the way across the tooth face. The initial contact of helical gear teeth is point
which changes into a line as the teeth come into more engagement.
In spur gears the line contact is parallel to the axis of rotation; in helical gear the
line is diagonal across the face of the tooth. Hence gradual engagement of the teeth
and the smooth transfer of load from one tooth to another occur.
This gradual engagement makes the gear operation smoother and quieter than
with spur gears and results in a lower dynamic factor, Kv. Thus, it can transmit heavy
loads at high speeds. Typical usage is automotive transmission for compact and quiet
drive.
The helix angle ψ, is always measured on the cylindrical pitch surface Fig. 11.8. ψ value
is not standardized. It ranges between 15o and 45o. Commonly used values are 15, 23,
30 or 45o. Lower values give less end thrust. Higher values result in smoother operation
nd more end thrust. Above 45o is not recommended.
Fig.11.9 Portion of helical rack
The circular pitch (p) and pressure angle (Ø) are measured in the plane of rotation, as in
spur gears. These quantities in normal plane are denoted by suffix n (p n, Øn) as shown
in Fig. 11.9.
pn = p cos ψ (11.1)
Normal module mn is
mn = m cos ψ (11.2)
d = Z m = Z mn / cos ψ (11.3)
In the case of helical gear, the resultant load between mating teeth is always
perpendicular to the tooth surface. Hence bending stresses are computed in the normal
plane, and the strength of the tooth as a cantilever beam depends on its profile in the
normal plane. Fig. 11.10 shows the view of helical gear in normal and transverse plane.
The following figure shows the pitch cylinder and one tooth of a helical gear. The normal
plane intersects the pitch cylinder in an ellipse.
The shape of the tooth in the normal plane is nearly the same as the shape of a spur
gear tooth having a pitch radius equal to radius Re of the ellipse.
Re = d/ (2cos2 ψ) (11.7)
The equivalent number of teeth (also called virtual number of teeth), Zv, is defined as
the number of teeth in a gear of radius Re:
2R e d (11.8)
Zv
m m cos2 ψ
Substituting mn = m cosψ, and d = Z m
Z
Zv (11.9)
cos3 ψ
When we compute the bending strength of helical teeth, values of the Lewis form factor
Y are the same as for spur gears having the same number of teeth as the virtual
number of teeth (Zv) in the Helical gear and a pressure angle equal to Øn.
Determination of geometry factor J is also based on the virtual number of teeth. These
values are plotted in Fig.11.11 and 11.12.
Fig 11.11 Geometry factor for use with a 75-tooth mating gear, pressure angle
(Фn) 20o, std. addendum of 1m and shaved teeth
HELICAL GEARS – J FACTOR MULTIPLIERS
Fig.11.12 J factor multipliers to be used with mating gears other than 75 teeth
3-dimensional view of the forces acting on a helical gear tooth is shown in the Fig.11.13.
Resolving Fn
Fr = Fn sin Øn (11.10)
Fr = Ft tan Ø (11.13)
Fa = Ft tan ψ (11.14)
Ft
F (11.15)
cosφ cosψ
Fig.11.14 illustrates the tooth forces acting on spur and helical gears. For spur gears,
the total tooth force consists of components tangential Ft and radial Fr forces. For helical
gears, component Fa is added and normal section NN is needed to show a true view of
total tooth force Fn.
Fig. 11.14 The comparison of force components on spur and helical gears
The vector sum Ft and Fa is labeled Fb; the subscript b being chosen because Fb is the
bending force on the helical tooth (just as Ft is bending force on the spur tooth).
The force component associated with power transmission is only Ft
1000W (11.16)
Ft
V
Fb = Ft / cos ψ (11.17)
Fr = Fb tan Øn (11.18)
Fr = Ft tan Ø (11.19)
σ K K (0.93K ) (11.21)
bm J
Introduction of constant 0.93 with the mounting factor reflects slightly lower sensitivity of
helical gears to mounting conditions. The J factor can be determined from Figs.11.15
and 1.16.
Ko = Overload factor which reflects the degree of non-uniformity of driving and load
torques. It is given in Table 11.1
Km = Load distribution factor which accounts for non uniform spread of the load across
the face width. It depends on the accuracy of mounting, bearings, shaft deflection and
accuracy of gears. Taken from Table 11.2.
Driven Machinery
Accuracy and mounting such that Over 2.0 Over 2.0 Over 2.0 Over 2.0
less than full-face contact exists
σe = σe’ kL kv ks kr kT kf km (11.23)
ks = surface factor, is taken from Fig. 11.18 based on the ultimate strength of the
kf = fatigue stress concentration factor. Since this factor is included in J factor, its value
is taken as 1.
Fig. 11.19 Miscellaneous effects factor km
km = Factor for miscellaneous effects. For idler gears subjected to two way bending,
= 1. For other gears subjected to one way bending, the value is taken from the Fig.5.
Use km = 1.33 for σut less than 1.4 GPa
σe
[σ] (11.24)
s
Hence the design equation from bending consideration is: σ ≤ [σ] (11.25)
In the case of spur gears of contact ratio less than 2, the theoretical length of
tooth contact is 1.0b.
With helical gears, the length of contact per tooth is b/cosψ and the helical action
causes the total length of tooth contact to be approximately b/cosψ times the contact
ratio (CR) at all times.
The AGMA recommends that 95% of this value be taken as the length of contact when
computing contact stress.
The contact stress equation is given as
Ft cosψ
σH Cp K Kv (0.93K ) (11.26)
bdI 0.95CR
o
C 0.564 (11.27)
1 μ2 1 μ2
1
2
E1 E2
Where E and µ are the young’s modulus and Poisson’s ratio. Suffix 1 is for pinion and 2
is for gear. The values are given in Table 11.4
Table 11.4 Elastic coefficient Cp for spur gears and helical gears, in MPa
sinφcosφ i
I (11.28)
2 i 1
Where the speed ratio i =n1 /n2 = d2 /d1 and Ø is the transverse contact angle.
Kv , Ko and Km as taken for bending stress calculation.
Table 11.5 Surface fatigue strength σsf’ (MPa) for metallic spur gears
(107 cycles life with 99% reliability and temperature <120oC)
Fig.11.20 Life Factor KL
K ratio of Brinell hardness of the pinion by Brinell hardness of the Gear. K H = 1.0 for K <
1.2
KR = Reliability factor, given in Table 11.6
KT = temperature factor,
= 1 for T≤ 120oC , based on Lubricant temperature.
Above 120oC, it is less than 1 to be taken from AGMA standards.
a. Crossed helical gears are identical with other helical gears but are mounted on non-
parallel shafts. They are basically non-enveloping worm gears since the gear blanks
have a cylindrical form.
b. The relationship between the shaft angle and the helix angles of mating gears is
σ = ψ1 ± ψ2 (11.33)
Where σ is the shaft angle. + sign is used when the gears have the same hand, and -
sign when they are opposite hand.
c. Opposite hand crossed helical gears are used when the shaft angle is small.
d. The most common shaft angle is 90 that results in mating gears with complementary
helix angles of the same hand.
e. The action of the crossed helical gears differs fundamentally from that of parallel
helical gears in that the mating teeth slide across each other as they rotate.
g. For a given shaft angle, the sliding velocity is least when the two helix angles are the
same.
h. Mating crossed helical gears must have the same pn and Øn but not necessarily the
same transverse p and Ø.
mn Z
dm Z (11.34)
cosψ
j. Furthermore, the velocity ratio is not necessarily the ratio of pitch diameters; it must be
calculated as the ratio of the numbers of teeth.
Fig. 11.22 View of the pitch cylinder of a pair of crossed –helical gear
CROSSED HELICAL GEAR - DESIGN TIPS
a. Crossed helical gears have very low load carrying capacities – usually less than a
resultant tooth load of 400 N.
c. Since they have point contact, to increase the load capacity contact ratios of 2 or
more are usually used.
d. Low values of pressure angle and relatively large values of tooth depth are commonly
specified to increase the contact ratio.
e. There are no standards for crossed helical gear tooth proportions. Many different
proportions give good tooth action.
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